Modular raceway

CROSS REFERENCE TO RELATED APPLICATIONS

0001This application claims the benefit of and incorporates by reference essential subject matter disclosed in U.S. Provisional Patent Application No. 60/634,308 filed on Dec. 8, 2004 entitled “Modular Raceway”.

TECHNICAL FIELD

0002This invention relates generally to a modular raceway systems.

SUMMARY OF THE INVENTION

0003This invention relates generally to a modular raceway system having raceway cover components of predetermined length fitted to wall brackets at predetermined intervals along a wall structure, some of which wall brackets are designed to provide a space or gap between the adjacent end portions of the raceway covers so as to receive electrical outlet/data ports at these locations for the wall support brackets, thereby avoiding the necessity for interrupting continuous cover components, thereby lending a more pleasing appearance to the overall installation.

0004The invention also provides for minimizing the need for raceway base channels, that match these cover components, such raceway base components being required only to form the wireway that houses power lines or other high voltage cables. Data and communication wiring of the low voltage variety is accommodated in adjacent wireways defined in large part by the wall itself, and enclosed by the elongated covers of predetermined length.

0005Another feature of the invention resides in the flexibility afforded in so called one piece raceway to form the support wireways for communication/data lines, low voltage wireways, support covers and enclosed wireway.

0006Still another feature of the present invention can be attributed to the unique configuration for the raceway covers whereby these covers include rearwardly projecting flanges that are adapted to be received by relieved top and bottom marginal edge portions of the support brackets. Gaps are provided at the support brackets for receiving device brackets which are also formed to fit the brackets. This unique configuration allows for outlet devices to be mounted not only in the front facing surface of the device bracket as in present day raceways, but also allows for the placement of outlet devices, including lamps, in the rearwardly projecting flanges of these device brackets. The brackets are mounted to the wall support brackets, which support brackets also support the end portions of the raceway covers, so as to define gaps in the covers to receive the device brackets.

0007The device brackets described in the preceding paragraph are configured to receive conventional outlet devices, ports and lamps as mentioned, and are fitted with device bracket covers. These device bracket covers have the same internal contour as the external contour of the raceway covers so as to overlie the raceway cover end portions, and thereby avoid the need for precisely cutting these raceway covers, as is characteristic of present day two piece metal and plastic raceway generally.

BRIEF DESCRIPTION OF THE DRAWINGS

0008<figref idref="DRAWINGS">FIG. 1</figref> is an exploded perspective view showing the various components of the present invention as they might appear relative to a wall structure.

0009<figref idref="DRAWINGS">FIG. 2</figref> is an exploded view of these components showing in greater detail the relationship between various components of a modular raceway system in accordance with the present invention.

0010<figref idref="DRAWINGS">FIG. 2</figref><i>a </i>is an assembled view of the components of the present invention.

0011<figref idref="DRAWINGS">FIG. 3</figref> is an exploded view showing in still greater detail the assembly process for mounting a device bracket to a wall bracket so that outlet devices can be provided in the device bracket, and covered by a device bracket cover.

0012<figref idref="DRAWINGS">FIG. 4</figref> is an exploded view showing the components illustrated in <figref idref="DRAWINGS">FIG. 3</figref> but also including other components in a modular raceway installation having separate upper and lower raceway covers to enclose the wireways which are provided for the data/communication cables and separately for the power lines.

0013<figref idref="DRAWINGS">FIGS. 5</figref><i>a, </i><b>5</b><i>b, </i><b>5</b><i>c, </i><b>5</b><i>d </i>and <b>5</b><i>e </i>show the arrangements for fabricating in the field a corner wall bracket from standard parts, some of which may be identical or similar to those used along the wall itself. Also shown are internal and external raceway corner cover components for use with these corner support brackets.

0014<figref idref="DRAWINGS">FIGS. 6</figref><i>a </i>and <b>6</b><i>b </i>are exploded views illustrating the end configuration for a typical modular raceway system in accordance with the present invention, and also illustrates an optional trim piece for accommodating additional wiring at the top of the raceway cover, as well as a prewired multiple outlet device raceway consisting of a base and a cover that might be accommodated in place of the base components to define the power wireway at the bottom of the modular raceway system. <figref idref="DRAWINGS">FIGS. 6</figref><i>a </i>and <b>6</b><i>b </i>also show a unique arrangement for accommodating at least one wiring device in the lower flange of the device bracket, and also shows a plurality of device bracket cover configurations for use in a modular raceway system in accordance with the present invention.

0015<figref idref="DRAWINGS">FIGS. 7</figref><i>a, </i><b>7</b><i>b </i>and <b>7</b><i>c </i>are sectional views through a modular raceway system in accordance with the present invention as compared to a convention 4000 series raceway of the type sold by the Wiremold Company of West Hartford, Conn. It will be noted that the conventional 4000 series raceway is of the so-called two piece metal raceway configuration, having a continuous base and raceway cover mated therewith, the cover having inturned flanges that mate with forwardly projecting flanges on the raceway base. The embodiments shown illustrate the invention, and the need for a contiguous raceway cover and raceway base components, with longitudinally spaced wall brackets that in turn support the raceway cover by rearwardly projecting flanges on the cover. Inturned lips on the covers are received in relieved marginal top and bottom edge portions of the wall brackets to support the covers in the absence of a continuous raceway base.

0016<figref idref="DRAWINGS">FIG. 8</figref> is a sectional view through a prior art modular raceway system.

DETAILED DESCRIPTION OF THE DRAWINGS

0017Considering <figref idref="DRAWINGS">FIG. 1</figref> in greater detail, a wall structure is indicated generally at W<b>1</b> and W<b>2</b> and defines an internal corner. The generally flat vertical walls are fitted with a modular raceway system in accordance with the present invention by placing mounting plates or wall mounting brackets, such as that shown at <b>10</b>,<b>10</b>′ at spaced intervals along the wall W<b>1</b> simply by providing a chalk line CL that is used to align the spaced mounting brackets <b>10</b>,<b>10</b>′. The chalk lines can be located at the opening lower edge <b>10</b><i>a, </i><b>10</b>′<i>a </i>in each of these brackets.

0018Modular raceway sections or assemblies, such as that indicated generally at <b>12</b>, can be prefabricated, and will therefore have a predetermined length so as to exceed slightly (L plus Δ) the distance L between longitudinal spaced mounting brackets <b>10</b>,<b>10</b>′. In fact these raceway sections overlap these wall mounting brackets a distance of Δ/2 so as to be conveniently mounted thereto. While the wall mounting brackets <b>10</b>,<b>10</b>′ are preferably secured to walls W<b>1</b>,W<b>2</b> by mounting screws such as indicated at <b>14</b>, the modular raceway sections <b>12</b>,<b>12</b><i>a </i>can be conveniently secured to these wall mounting brackets without the necessity for such fasteners in a manner to be described in greater detail hereinafter.

0019The raceway sections <b>12</b> and <b>12</b><i>a </i>are provided so that end portions of the raceway sections <b>12</b> and <b>12</b><i>a </i>define a gap G therebetween. This gap G is slightly less than the longitudinal dimension L<b>1</b> of the wall mounting bracket <b>10</b> so as to provide for the necessary overlap, Δ, to support the raceways sections.

0020In accordance with the present invention this gap G is utilized to provide a convenient location for accommodating a device bracket, such as that indicated at <b>15</b>. The device bracket <b>15</b> includes upper and lower marginal edges defining rearwardly formed flanges <b>15</b><i>a </i>and <b>15</b><i>b </i>that are designed to be snap fit upon assembly with the wall mounting support bracket <b>10</b>. The wall mounting support bracket <b>10</b> defines relieved upper and lower marginal edges <b>10</b><i>b</i>,<b>10</b><i>c </i>that receive these flanges <b>15</b><i>a </i>and <b>15</b><i>b, </i>and more particularly that receive the down turned lips on each device bracket <b>15</b> as will be described in greater detail hereinafter.

0021Outlet devices such as shown at <b>16</b> and <b>18</b> are mounted to the device bracket, and a device bracket cover <b>20</b> is configured to be received by the end portions of the raceway sections <b>12</b> and <b>12</b><i>a, </i>and to overly these end portions to hide any uneven cut required on these raceway sections <b>12</b> and <b>12</b><i>a. </i>

0022As suggested in <figref idref="DRAWINGS">FIG. 1</figref> the raceway assemblies <b>12</b> and <b>12</b><i>a </i>are designed to be snapped together and are preferably fabricated in predetermined lengths (between 4 and 8 feet in length) and can be mounted to the wall mounting bracket <b>10</b> and nevertheless slid (side to side) so as to fit the wall, without the need for any cutting. Although these raceway sections are shown with wiring provided in their separately defined wireways, such a preassembly is not required, and instead the raceway covers can be separated until after installation of the wiring, following which the covers can be snapped in place in the manner to be described in greater detail hereafter.

0023Thus, the raceway sections <b>12</b> and <b>12</b><i>a </i>are illustrated in exploded relationship, after accomplishment of the forgoing steps and preparatory to installing the outlet devices <b>16</b> and <b>18</b> to the wires <b>30</b> and <b>40</b> provided in the separate wireways in accordance with conventional practice.

0024The final step in the process is snapping the device bracket cover <b>20</b> in place to afford an essentially tamperproof wireway installation that is designed to require a proprietary tool (not shown) for removal, and for access to the wiring in the raceway channels, or wireways.

0025As shown in <figref idref="DRAWINGS">FIG. 2</figref>, the wall mounting bracket <b>10</b> can be provided in different sizes, but preferably is approximately 12 inches in length so as to readily accommodate a single row or stack of outlet devices such as described previously with reference to <figref idref="DRAWINGS">FIG. 1</figref>. Nevertheless, a 2-foot wall mounting bracket can be utilized where the need exists for fitting the standard predetermined length raceway sections <b>12</b>,<b>12</b><i>a </i>to a wall of such length that it is not readily divisible by the standard predetermined 4 to 8 foot length sections supplied to the installer. Thus, the gap G provided between the adjacent raceway sections <b>12</b> and <b>12</b><i>a </i>can be varied significantly. Another feature of the invention resides in the fact that a relatively smaller or shorter length wall mounting bracket <b>10</b>′ might be used in the event no outlet devices, or outlet device bracket, is necessary between two adjacent raceway sections. In such case the gap G will be short enough to be readily spanned by a bracket cover of even shorter length than that illustrated at <b>200</b> in <figref idref="DRAWINGS">FIG. 2</figref>. The bracket cover <b>200</b> is designed to accommodate a gap between the adjacent raceway sections of larger size and length and can be used by the installer to make up the raceway to fit wall segments that may not be long enough to accommodate the standard predetermined raceway sections described previously.

0026Still with reference to <figref idref="DRAWINGS">FIG. 2</figref>, a power raceway channel <b>400</b> is shown that is designed to be received between forwardly projecting flanges <b>10</b><i>d </i>and <b>10</b><i>e </i>defined for this purpose in the wall mounting bracket <b>10</b>. The forwardly projecting flange <b>10</b><i>d </i>has a v-shaped notch <b>10</b><i>f </i>which cooperates with a wall segment on upper flange <b>400</b><i>b </i>on power channel <b>400</b> and forwardly projecting flange <b>10</b><i>e </i>has a raised portion <b>10</b><i>g </i>which cooperates with a v-shaped notch <b>400</b><i>a </i>on lower flange <b>400</b><i>c </i>to support the power channel <b>400</b> in a snap fit assembly adjacent the spaced end portions of the power channel as best seen in <figref idref="DRAWINGS">FIGS. 2</figref><i>a </i>and <b>7</b><i>c. </i>This snap fit arrangement affords ease of assembly for the installer, and avoids the need for fasteners. The smaller support or mounting bracket indicated generally at <b>10</b>′ is also provided with a flange <b>10</b>′<i>d, </i>and the bottom marginal edge of this smaller bracket <b>10</b>′ is designed to support the rear corner of the forwardly open power channel <b>400</b>. The upper flange <b>10</b>′<i>d </i>like the flange <b>10</b><i>d </i>for the bracket <b>10</b> is integrally formed with the bracket as indicated by the opening <b>10</b><i>h </i>in the bracket <b>10</b>, and the opening <b>10</b>′<i>h </i>in the bracket <b>10</b>′.

0027The power channel <b>400</b> is forwardly open, defining a channel for receiving the power cables (not shown). Upper and lower flanges <b>400</b><i>b </i>and <b>400</b><i>c </i>thereof cooperate with rearwardly projecting flanges of a raceway cover <b>500</b> to span only the power channel. The cover <b>500</b> is a snap-fit on the power channel <b>400</b> by reason of the raceway cover <b>500</b> top and bottom flanges being spread during assembly so as to fit over the power channel flanges <b>400</b><i>b </i>and <b>400</b><i>c. </i>An upturned lip <b>500</b><i>a </i>on the cover <b>500</b>, defined at the trailing edge of the lower flange <b>500</b><i>b </i>fits within the relieved area <b>10</b><i>c </i>defined for this purpose on the wall mounting bracket <b>10</b>. The forwardly projecting marginal edge of the flange <b>400</b><i>b </i>is received in the V-shaped notch <b>500</b><i>c </i>defined between the top flange <b>500</b><i>d </i>of the raceway cover <b>500</b> and the front surface of said cover.

0028A top raceway cover <b>600</b> has a rearwardly projecting flange <b>600</b><i>a </i>with a downturned lip <b>600</b><i>b </i>to be received in the relieved area <b>10</b><i>b </i>of the wall mounting bracket <b>10</b>. The forwardly projecting marginal edge of the upper flange <b>10</b><i>d </i>is received in a v-shaped notch <b>600</b><i>c </i>defined between a lower flange <b>600</b><i>d </i>and the front surface of the cover <b>600</b>. The entire assembly is best illustrated in <figref idref="DRAWINGS">FIG. 2</figref><i>a. </i>The wall mounting bracket <b>10</b> having it's forwardly projecting flange <b>10</b><i>d </i>provided between its upper and lower marginal edges, to cooperate with a lower flange <b>10</b><i>e </i>so as to receive the power channel therebetween. The top and bottom raceway covers <b>600</b> and <b>500</b> respectively are shown assembled with the wall mounting bracket <b>10</b>, each having a top and a bottom lip, <b>600</b><i>b </i>and <b>500</b><i>a </i>respectively, as well as adjacent interlocking portions <b>600</b><i>c </i>and <b>500</b><i>c </i>respectively, to form a unitary structure once assembled.

0029Still with reference to <figref idref="DRAWINGS">FIG. 2</figref>, it is a feature of the present invention that only the wireway which is intended to accommodate the power lines need have a back wall, and the wireway which accommodates the data/communication wiring can be configured without any need for a back wall. As an alternative to the two-piece raceway cover <b>500</b>,<b>600</b> a one-piece cover is show in phantom line at <b>300</b>. The raceway cover <b>300</b> in <figref idref="DRAWINGS">FIG. 2</figref> has upper and lower marginal edges defining rearwardly projecting flanges <b>300</b><i>a </i>and <b>300</b><i>b, </i>with upturned and downturned lips <b>300</b><i>c </i>and <b>300</b><i>d </i>respectively, designed to be received in the relieved areas <b>10</b><i>b </i>and <b>10</b><i>c </i>defined for this purpose in the wall mounting bracket <b>10</b>. As mentioned previously only the end portions of the raceway cover <b>300</b> are received in these relieved areas, and a gap G is purposefully provided at the wall mounting bracket <b>10</b> to receive a device bracket, and device bracket cover, all as described previously with reference to <figref idref="DRAWINGS">FIG. 1</figref>.

0030Thus, two different raceway configurations are illustrated in <figref idref="DRAWINGS">FIG. 2</figref>, one having a single raceway cover <b>300</b> spanning both wireways, most useful where both wireways are used for communication or data cables for low voltage. More common perhaps would be the need for providing a wireway capable also of accommodating higher voltage wiring, in such case the elongated power channel <b>400</b>, equal in length to the raceway section <b>12</b> in <figref idref="DRAWINGS">FIG. 1</figref>, is first assembled with the wall mounting brackets <b>10</b>,<b>10</b>′.

0031<figref idref="DRAWINGS">FIG. 3</figref> shows the device bracket <b>15</b> which is assembled with the wall mounting bracket <b>10</b>, and more particularly in the gap defined for this purpose between the adjacent raceway sections <b>12</b> and <b>12</b><i>a </i>(reference <figref idref="DRAWINGS">FIG. 1</figref>) as well as the devices <b>16</b> and <b>18</b> (also referenced in <figref idref="DRAWINGS">FIG. 1</figref>). The device bracket <b>15</b> includes rearwardly projecting flanges <b>15</b><i>a </i>and <b>15</b><i>b </i>that define inturned lips <b>15</b><i>c </i>and <b>15</b><i>d </i>respectively. These lips are shaped to be received in the relieved regions <b>10</b><i>b </i>and <b>10</b><i>c, </i>of wall mounting bracket <b>10</b>, again for a convenient snap fit assembly therewith, that avoids the need for screw fasteners or the like.

0032The device bracket cover <b>20</b>, which is used where a device bracket <b>15</b> is accommodated on the wall mounting bracket <b>10</b>, necessarily requires that openings be defined to provide access to outlet devices <b>16</b> and <b>18</b>. Finally, device faceplates <b>17</b> and <b>19</b>, finish the installation. These faceplates may also be snap fit, or in the alternative rely upon screw fasteners for installation. An alternative device bracket cover <b>20</b>′ is also shown in <figref idref="DRAWINGS">FIG. 3</figref>, and it is a feature of the device bracket covers <b>20</b>,<b>20</b>′ that notches <b>20</b><i>a</i>,<b>20</b>′<i>a </i>are provided in an unobtrusive design that will allow a special tool (not shown) to be inserted in the notches for disassembly of these device covers only as a result of utilizing such a tool for this purpose, and thereby avoiding unauthorized access to the raceway interior.

0033<figref idref="DRAWINGS">FIG. 4</figref> shows the relative dimensional relationship between the various components of the present invention, and shows how each of these components can be slid together upon assembly with one another, either upon installation, or removal, or in retrofitting a particular raceway installation with the split cover arrangement shown.

0034This view also illustrates the dimensional range for the gap G, between the raceway cover components (4.5. to 6 inches) and shows that these raceway cover segments need be “rough-cut” only to allow the device bracket to fit between these cover end portions. The device bracket cover <b>20</b> is designed to overlie the raceway cover components with the internal contour of the raceway cover <b>20</b> conforming to the external contour of the raceway cover segments or components, hiding the “rough-cut” raceway cover end portions.

0035<figref idref="DRAWINGS">FIGS. 5</figref><i>a</i>-<b>5</b><i>e </i>are intended to illustrate another novel feature of the modular raceway system in accordance with the present invention, whereby installations can be conveniently made in spite of minor variations in the perpendicularity of the walls defining both the internal and external corners of the room.

0036Wall mounting brackets <b>10</b>, <b>10</b> are preferably used in pairs to form these internal and external corners and in the case of the internal corners lines of weakening <b>10</b><i>i, </i><b>10</b><i>j </i>or break off tabs are provided in the wall mounting bracket flange <b>10</b><i>e </i>for this purpose. It will also be apparent that fabricating these internal and external corner brackets in the field, as shown in <figref idref="DRAWINGS">FIGS. 5</figref><i>a</i>-<b>5</b><i>e, </i>will lead to ease of installation of a kind not possible with prior art raceway configurations, particularly with present day raceways that rely on special fittings for running two-piece raceway around internal and external corners.

0037Still with reference to <figref idref="DRAWINGS">FIGS. 5</figref><i>a</i>-<b>5</b><i>e, </i>the raceway cover configuration can be seen to employ the same individually paired wall mounting brackets to support the raceway covers, and the relatively simple process of angle cutting the rearwardly projecting flanges of the cover components can lead to a finished appearance for the resulting installation that is not possible with prior art raceway installations generally.

0038<figref idref="DRAWINGS">FIGS. 6</figref><i>a </i>and <b>6</b><i>b </i>illustrates additional features of the modular raceway system of the present invention. An optional trim piece <b>700</b> can accommodate additional wiring, and can be adhered to the top flange of the raceway cover system described previously.

0039A polymeric wire holder <b>800</b> is provided of such a size that it can be received in the space which defines the wireway for the data and communication wiring.

0040Where the raceway will be preassembled at the factory, wiring holders that also serve as bumpers during shipment can be fabricated from a polymeric material and serve to hold the various assembled components of the raceway system in place during transit, and even during installation, further facilitating the installers task upon installation of a raceway such as described here. <figref idref="DRAWINGS">FIG. 6</figref><i>b </i>also illustrates a further embodiment of the present invention where prewired multiple device raceway <b>450</b> can be accommodated in one or the other of the two wireways in the event outlet plugs are desired intermediate the spaced wall mounting brackets. As shown, a PLUGMOLD style raceway is installed in the upper wireway, and is designed for retention by the wall mounting brackets <b>10</b>. As shown this PLUGMOLD raceway has its own prefabricated raceway cover <b>450</b><i>a. </i>Other preassembled components can be accommodated, such as the raised outlet devices indicated at <b>550</b> in <figref idref="DRAWINGS">FIG. 6</figref><i>b. </i>Specially fabricated devices such as those shown at <b>550</b> and <b>560</b> are designed to project through the openings provided for this purpose in the device bracket cover <b>20</b>, increasing the number of electrical outlet plugs in each such device.

0041<figref idref="DRAWINGS">FIG. 8</figref> illustrates a typical prior art 4000 series two piece raceway having continuous base raceway channel and continuous cover components fitted thereto, as presently offered by The Wiremold Company of West Hartford, Conn., United States.

0042<figref idref="DRAWINGS">FIG. 7</figref><i>a </i>is a section view taken through a mounting bracket location to illustrate the installation of a device bracket, and device bracket cover together with the devices supported in that device bracket. This view also illustrates a convenient grounding arrangement in the form of a screw S, which is threadably received in the forwardly projecting flange in the wall mounting bracket, and grounds the wall mounting bracket to the forwardly open power channel <b>400</b>. This particular view shows a single raceway cover rather than the split raceway cover design that is the subject of <figref idref="DRAWINGS">FIG. 4</figref>.

0043<figref idref="DRAWINGS">FIG. 7</figref><i>b </i>shows the single cover configuration through a section of the assembled raceway section at a device mounting bracket attached to a wall mounting bracket.

0044Finally, <figref idref="DRAWINGS">FIG. 7</figref><i>c </i>shows a section through the raceway, similar to <figref idref="DRAWINGS">FIG. 7</figref><i>b </i>but illustrating the split cover raceway, configuration such as that illustrated in <figref idref="DRAWINGS">FIGS. 2 and 4</figref>.

0045While the present invention has been illustrated and described with respect to a particular embodiment thereof, it should be appreciated by those of ordinary skill in the art that various modifications to this invention may be made without departing from the spirit and scope of the present invention.